Disc packaging device

ABSTRACT

The invention relates to a packaging device for securely holding and storing a plurality of discs, comprising a base, and an elongated spindle centrally situated on the base and projecting from the top side of the base in a substantially perpendicular orientation to the base, wherein the spindle is configured to receive and secure a plurality of discs to the base. The packaging device further comprises a removable, substantially circular protective endplate having a central opening for engaging with the top portion of the spindle, the endplate being disposed atop the plurality of discs to protect and secure the plurality of discs to the spindle and base.

FIELD OF THE INVENTION

The invention relates generally to a disc packaging device for packaging a plurality of discs, e.g., optical discs such as CD-Rs, CD-RWs, or DVDs.

BACKGROUND OF THE INVENTION

In recent years optical discs have become an increasingly popular choice as a medium for data storage. The availability of recordable optical discs, including compact disc-recordable (CD-R), compact disc-rewritable (CD-RW) or other optical media such as recordable digital versatile discs (DVDs) allow consumers to record their own collections of music, video, or other data. Blank optical discs are commonly distributed and sold commercially in packages containing at least 10 discs. Some of these packages are constructed to hold a plurality of optical discs, and may be secured by a central spindle and covered with a protective case.

The common “cakebox” disc package comprises a base and a central spindle, with the discs stacked on the base and around the spindle, along with a cylindrical dome cover which protects the discs from damage during shipping and handling. This type of package requires a mechanism for ensuring that the cover can be locked securely onto the base during shipping. Such mechanisms include buckling sheets, coupling grooves, or snap fit mechanisms, as shown, for example, in US 2004/0182725, US 2004/0251150, and US 2004/0099548. Thus this type of disc packaging device requires that the base and cover be designed and manufactured with an attachment mechanism. Accordingly, such designs invariably require more complex manufacturing procedures and will also require an additional packaging step of securing the cover to the base before the packages are shipped. A design requiring a mechanism to connect the cover to the base typically results in the formation of a base that protrudes beyond the diameter of the cover, and thus the base is left exposed and may be subject to physical damage during shipping.

However, if protecting or covering of the base is desired, an additional packaging step is required. In addition, the protrusion or lip of the base beyond the cover also results in a shape for the assembled package that is not perfectly cylindrical with respect to the cover, and therefore takes up additional space in shipping, storage and display.

An alternative packaging system known in the art includes two endcaps, each of which has a central protrusion portion formed on one surface. An opposing surface has a plurality of ribs extending radially outwardly from an inner rim to an outer rim, which provide stability to the endcap. A stack of disks is disposed between the protrusion portions of the endcaps. Some versions of this packaging device also include a central spindle which further secures the discs. The spindle may be inserted through holes in the centers of each endcap, or each endcap may have a centered twist lock recess for accepting a twist lock spindle. Packaging systems of this type are illustrated in, for example, U.S. Pat. No. 6,296,114 and US 2004/0154938. These packages require an additional band, plastic shield or flexible wrap which is wrapped around the discs to protect the stack of discs and to provide structural integrity to the package. Because the packaging device is not stable until this outer shield or wrap is applied, assembly of this type of package may require additional steps using a support rack, as shown in US 2004/0154938.

SUMMARY OF THE INVENTION

One aspect of the invention is to provide a disc packaging device to simplify design and manufacture and to significantly reduce manufacturing, shipping and storage expenses to the trade. A further aspect of the invention is to provide a disc packing device which reduces source material used in manufacture. A further aspect of the invention is to provide a disc packing device wherein the assembled packages are cylindrical and take up minimal space in shipping or display.

In one aspect, there is provided a disc packaging device comprising a base, an elongated spindle comprising a top portion and a bottom portion, the spindle being centrally located on the base and projecting from the top side of the base in a substantially perpendicular orientation to the base, wherein the spindle is configured to receive and secure a plurality of discs to the base; a removable, substantially circular protective endplate having a central opening for engaging with the top portion of the spindle, the endplate being disposed atop the plurality of discs to protect and secure the plurality of discs to the spindle and base; and sheet material wrapped around the plurality of discs and at least partly around the base and the endplate to enclose the plurality of discs securely between the base and endplate.

In another aspect, there is provided a disc packaging device which comprises attachment means for attaching and securing the spindle to the base. In various embodiments, the attachment means is selected from the group consisting of a twist lock connection, coupling grooves, a snap fit mechanism, a screw-on locking nut configured with a threaded spindle wherein the nut may be secured from the top side or bottom side of the base, and a detachable snap-on connection.

The invention further comprises a disc packaging device wherein the base has a centrally located opening, and wherein the spindle has a flange at the bottom portion of the spindle, wherein the flange is configured to fit through the opening and engage the bottom side of the base to secure the spindle to the base. In a further embodiment, the spindle further comprises a backing ring at the bottom portion of the spindle and above the flange, positioned so as to contact the upper side of the base and further secure the spindle to the base.

In another variation of the above embodiments, the base and spindle are formed of unitary construction. In some embodiments the base and spindle are formed from extruded molding fabrication methods. In various embodiments, the base and spindle are made from a material selected from the group consisting of plastic, cardboard, metal, or a combination thereof. In various embodiments, the endplate is made of a material selected from the group consisting of plastic, paper, cardboard, metal, or a combination thereof. In various embodiments the sheet material is shrink-wrap film or stretch film.

In another aspect of the above embodiments, the sheet material wraps the device sufficiently to protect the device from the environment during shipping, handling and storage. In a further aspect of the above embodiments, the sheet material wraps the device sufficiently to maintain a water resistant environment for the discs.

In further embodiments of the invention, the base has an annular outer rib at an outer edge of the bottom side of the base, which allows for easier removal of the outer wrap from the package.

In various embodiments of the invention, the plurality of discs are optical data discs, for example, read only optical disks such as CD, CD-ROM, DVD-ROM and DVD-Video; write-once discs such as CD-R, DVD-R, WORM and magneto-optic discs; or rewritable discs such as CR-RW, DVD-RAM, DVD-RW and MO. In some embodiments, the device is configured to hold at least 25 discs.

In a further embodiment, the invention is directed to a packaging device for securely holding and storing a plurality of discs, the device comprising: a base having a top side and a bottom side; an elongated spindle comprising a top portion and a bottom portion, the spindle being centrally located on the base and projecting from the base in a substantially perpendicular orientation to the base, wherein the spindle is configured to receive and secure a plurality of discs to the base; a removable, substantially circular protective endplate having a central opening for engaging with the top portion of the spindle, the endplate being disposed atop the plurality of discs to protect and secure the plurality of discs to the spindle and base; and attachment means for securing the endplate to the spindle.

In various embodiments, the attachment means is selected from the group consisting of a twist lock connection, a screw on locking nut configured with a threaded spindle wherein the nut may be secured from the top side of the lid, and a detachable snap-on connection. In alternative embodiments of the invention, the base and spindle are formed of unitary construction.

In further embodiments the device further comprises an outer wrap of a sheet material to protect the discs from dust, light and water during transportation and storage.

In preferred embodiments, the base and the endplate are of the same diameter as the packaged discs; thus the packages take up the minimum amount of space, allowing for efficient packing for shipping or display. In some embodiments, the base has an annular rib on the periphery of the lower side of the base, which allows for easy removal of the outer wrap from the package.

The invention is further directed to a method for securely holding and storing a plurality of discs, the method comprising providing a packaging device comprising: i) a base having a top side and a bottom side; ii) an elongated spindle comprising a top portion and a bottom portion, the spindle being centrally located on the base and projecting from the top side of the base in a substantially perpendicular orientation to the base, wherein the spindle is configured to receive and secure a plurality of discs to the base; and iii) a removable, substantially circular protective endplate having a central opening for engaging with the top portion of the spindle, the endplate being disposed atop the plurality of discs to protect and secure the plurality of discs to the spindle and base; stacking a plurality of discs onto the spindle; installing a endplate on the discs; and wrapping the plurality of discs and at least part of the base and the endplate with sheet material to enclose the plurality of optical discs securely between the base and endplate.

In some embodiments of the method, the packaging device further comprises attachment means for attaching and securing the spindle to the base, and the method further comprises the step of attaching the spindle to the base. In further embodiments of the method, the sheet material is shrink-wrap film and the method further comprises the step of heating the shrink-wrap film to shrink the film after the wrapping step.

In another aspect of the above embodiments, the sheet material wraps the device sufficiently to protect the device from the environment during shipping, handling and storage. In a further aspect of the above embodiments, the sheet material wraps the device sufficiently to maintain a water resistant environment for the discs.

Additional objects, features and advantages of the invention will be set forth in the description which follows, and in part, will be obvious from the description, or may be learned by practice of the invention. The embodiments, aspects, objects, features and advantages of the invention may be realized and obtained by means of the instrumentalities and combination particularly pointed out in the appended claims. In addition, as disclosed herein, it is intended that any one or more features, aspects or embodiments of the invention may be combined or used in connection or interchangeably with any other features, aspects or embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a base and spindle according to one aspect of the invention.

FIG. 2 is an exploded perspective view showing a disc packaging device according to one aspect of the invention.

FIG. 3 is an exploded perspective view of the bottom side of a base and spindle detailing an interlocking connection according to one aspect of the invention.

FIG. 4 is a perspective view of a disc packaging device with an outer wrap according to one aspect of the invention.

DETAILED DESCRIPTION OF THE INVENTION

A “base,” as defined herein is any bottom, foundation, seat, support, stand or pedestal that may be used to support a plurality of discs and a spindle. In one aspect, the base may be flat and substantially circular. In another aspect, the base may be square or any other suitable shape designed for securing and storing a plurality of discs. In another aspect, the base may comprise means for attachment or coupling to a spindle. Such means of attachment may be configured as an element of the base, configured as a element of the spindle, or configured as an element of the base and spindle for securely coupling the spindle to the base. In one variation, the base may have substantially smooth upper and lower surfaces, or the base may have additional grooves, ribs, or other features on the upper and/or lower surface as may be required to provide a base or structure to stabilize the device and/or to protect the coupling or attachment means to the spindle.

The term “device”, as used herein, is intended to include an assemblage of components, packaging assembly or packaging system for packaging and storing a plurality of discs. Such devices are related to those known in the art that are used as “bulk packages.” Non-exclusive components may include a base, a spindle and outer securing means, such as a wrapping material and the like, for securing the plurality of discs onto the base and spindle.

A “spindle,” as defined herein, is any rod, bar shaft, axle, pole, vertical or upright element that is configured to receive and secure a plurality of discs to a base. The spindle may be cylindrical in form, rectangular, triangular, oblong or may have any other shapes configured such that a plurality of discs may be stacked and secured to the base. In one variation, the spindle may comprise means for attachment to a base or endplate at either or both ends. The spindle may be of solid construction, or may be hollow, recessed or chambered. The spindle may be of constant width over its length, or may be tapered or widened at one or both ends or at one or more regions along its length. The width of the spindle at any one point will be configured to provide at least one contact point with the discs to ensure that the discs will be secured to the device.

As shown in FIG. 1, in one aspect of the invention, the disc packaging device comprises a base 10 having a top side and a bottom side. The disc packaging device further comprises a spindle 20 centrally situated on the base and which projects from the base 10 in a substantially perpendicular orientation to the base 10. As shown in FIG. 1, in one aspect of the invention, the disc packaging device further comprises attachment means for securing the spindle 20 to the base 10.

The attachment means, according to one embodiment of the invention as shown in FIG. 3, is a twist lock connection between the spindle and the base 10. The spindle 20 comprises a flange 22 on the bottom portion of the spindle 20. The flange 22 comprises two rectangular protrusions 23 located on opposite sides of the flange 22. The base 10 comprises a central through hole 13 for receiving the flange 22. The through hole 13 comprises two rectangular notches 17 for receiving the rectangular protrusions 23 on the flange 22. The flange 23 is inserted into the base 10 via the central through hole 13. Rotating the spindle 20 positions the rectangular protrusions 23 onto the bottom surface of the base 10 and securely locks the spindle onto the base. The bottom of the base 10 also has two curved ribs 16 at the periphery of the through hole 13, which restrict further rotation of the inserted spindle 20. As shown in the embodiment illustrated in FIG. 3, the spindle 20 further comprises a backing ring 21 (See FIG. 1) positioned to rest on the upper surface of the base 10 once the spindle 20 has been inserted, further securing the spindle 20 to the base 10.

In further embodiments of the invention, the base 10 further comprises coupling grooves formed on the bottom surface of the base 10 to one side of each notch 17. Rotating the spindle 20 positions the rectangular protrusions 23 into the coupling grooves. In various embodiments, the twist lock connection between the base 10 and spindle 20 may vary in form. For example, the number and shape of the protrusions 23 and corresponding notches 17 and, when present, coupling grooves, may be a single protrusion, or may have more than two protrusions. The protrusions 23 and corresponding notches 17 and, when present, coupling grooves, may be rectangular or of any other shape sufficient to secure or interlock the spindle to the base.

In further embodiments of the invention, the attachment means may include other attachment means (not shown in the Figures) known in the art for securing the spindle 20 to the base 10. For example, the attachment means may include a screw on, with or without a locking nut configured with a threaded spindle 20 wherein, when present, the nut may be secured from the top side, bottom side, or both sides of the base 10, coupling grooves, a snap fit mechanism, or a detachable snap-on connection.

In alternative embodiments of the invention, the base 10 and spindle 20 are formed of unitary construction, such that no attachment means is required. As used herein, the term unitary construction means that the base and spindle may be made as a single unit or element, and may be typically formed from a light weight and inexpensive molded plastic or the like. In some embodiments, the base 10 and spindle 20 are formed from extruded molding fabrication methods. The base 10 and spindle 20 may be made from material such as plastic, cardboard, metal, or a combination thereof.

Once the spindle 20 is attached to the base 10, as shown in FIG. 1, the combined base with spindle provides a stable platform for loading a plurality of discs 30. As shown in FIG. 2, the plurality of discs 30 are loaded onto the base 10 with the spindle 20 passing through the central holes 31 of the discs 30. In one aspect of the invention, the disc packaging device further includes a removable, substantially circular protective endplate 40 having a central opening 41 for engaging with the top portion of the spindle 20, the endplate 40 being disposed atop the plurality of discs 30 to protect and secure the plurality of discs 30 to the spindle 20 and base 10.

As shown in the embodiment of the invention illustrated in FIG. 2, the endplate 40 is a flat disc with a central hole 41, making it particularly simple to manufacture and to assemble onto the disc package. In various embodiments, the endplate 40 may be square or any other suitable shape. In one aspect, the end plate may be a dud or non-functioning disc. In one aspect, the endplate may have a lip extending downward from the periphery of the endplate 40 to at least partially cover one or more of the plurality of discs 30. The endplate 40 may have additional ribs, grooves or other features on the upper, lower, or both sides of the end plate for ease of packaging of the device and for protecting the discs from environmental contact or physical damage. In place of a central hole 41, the endplate 40 may have a recess or protrusion configured for engaging with the upper portion of the spindle 20. In preferred embodiments, the endplate 40 as well as the base 10 are of the same diameter as the packaged discs 30; thus in this configuration, the packages take up the minimum amount of space, allowing for efficient stacking of devices, packing for shipping or display of the devices.

The endplate 40 may be made from a material such as plastic, cardboard, paper, metal, or a combination thereof. The endplate 40 may be colored or printed, and may include information such as text, logos, images or other indicia of information or advertisement.

The disc packaging device further comprises an outer wrap 50 of material, such as a sheet material. The sheet material is wrapped around the plurality of discs 30 and at least partly around the base 10 and the endplate 40 to enclose the plurality of discs 30 securely between the base 10 and the endplate 40. In some embodiments, wherein the disc packaging device does not comprise an endplate, the sheet material is wrapped at least partly around the base 10 and the uppermost of the plurality of discs 30, to enclose the plurality of discs 30 and secure them to the base 10. In further embodiments, the sheet material may completely cover the surface of the uppermost of the plurality of discs 30.

The sheet material protects the discs from the environment, including dust, light and water during transportation and storage. The sheet material may be shrink-wrap film, stretch film, or any other flexible membrane. The wrap 50 may be transparent, or may be colored or printed, and may include information such as text, logos, images or other indicia. The wrap 50 may have perforations at one or more locations to allow for easier removal of the wrap by the consumer. A particular advantage of the present packaging device is that the device is designed to utilize a minimum amount of wrapping materials to conserve and significantly reduce waste and associated packaging costs when compared to existing packaging devices that are commercially available.

In alternative embodiments, the disc packaging device includes attachment means for securing the endplate 40 directly to the spindle 20. In one embodiment, the attachment means comprise a screw on locking nut configured with a threaded spindle 20, wherein the nut is secured from the top side of the endplate 40. In alternative embodiments the attachment means may include other means known in the art, for example, a twist lock connection, or a detachable snap-on connection.

In these embodiments, the attachment of the endplate 40 to the base 10 serves to enclose the plurality of discs 30 securely between the base 10 and endplate 40. The disc packaging device according to these aspects of the invention may optionally also include an outer wrap of a sheet material to protect the discs from the environment, including from dust, light and water during transportation and storage.

The disc packaging device of the invention may be configured to hold varying numbers of discs, depending upon the length of the spindle 20. Spacers may also be inserted on the spindle 20, typically at the bottom or the top of the plurality of discs 30, in order to adjust the number of discs fitting in the device. In various embodiments, the device is configured to hold at least 10, at least 25, at least 50, or at least 100 discs.

The plurality of discs 30 for packaging in the device may be optical data discs, for example, read only optical disks such as CD, CD-ROM, DVD-ROM and DVD-Video; write-once discs such as CD-R, DVD-R, WORM and magneto-optic discs, or rewritable discs such as CD-RW, DVD-RAM, DVD-RW and MO.

The invention further provides a method for securely holding and storing a plurality of discs 30, as shown in FIG. 2 and FIG. 4. The method comprises providing a packaging device as shown in FIG. 2, comprising a base 10, an elongated spindle 20 being centrally located on the base 10 and projecting from the top side of the base 10 in a substantially perpendicular orientation to the base 10, and a removable, substantially circular protective endplate 40. The method further comprises the steps of stacking a plurality of discs 30 onto the spindle 20, disposing the endplate 40 atop the plurality of discs 30, and wrapping the plurality of discs 30 and at least part of the base 10 and the endplate 40 with an outer wrap 50 of sheet material to enclose the plurality of optical discs 30 securely between the base 10 and endplate 40. In some embodiments, wherein the disc packaging device does not comprise an endplate, the sheet material is wrapped at least partly around the base 10 and the uppermost of the plurality of discs 30, to enclose the plurality of discs 30 and secure them to the base 10. In further embodiments, the sheet material may completely cover the surface of the uppermost of the plurality of discs 30.

For those embodiments of the invention in which the packaging device further comprises attachment means for attaching and securing the spindle 20 to the base 10, the packaging method further comprises the step of attaching the spindle 20 to the base 10.

In some embodiments of the invention, the sheet material is shrink-wrap film, and the packaging method further comprises the step of heating the shrink-wrap film to shrink the film, as is known in the art, following the wrapping step.

In the embodiment shown in FIG. 3, the base has an annular outer rib 11 on the lower side of the base 10 at the periphery of the base 10, as well as a concentric annular inner rib 12. As shown in FIG. 3, these ribs are circular, but they may have other shapes. When the wrapping material 50 is wrapped around the plurality of discs 30 and over at least a portion of the base 10, the annular outer rib 11 raises the edge of the wrap 50 off the bottom surface of the base 10, providing room for the user to grasp the edge of the wrap 50 and tear it to unwrap the device.

After the outer wrap 50 is removed, the endplate 40 is removed, thereby exposing the discs for use. The discs can be stored on the base spindle assembly, and may be covered by the endplate 40 when not in use. 

1. A packaging device for securely holding and storing a plurality of discs, the device comprising: a) a substantially circular base having a top side and a bottom side; b) an elongated spindle comprising a top portion and a bottom portion, the spindle being centrally situated and secured to the base and projecting from the top side of the base in a substantially perpendicular orientation to the base, wherein the spindle is configured to receive and secure a plurality of discs to the base; and c) sheet material wrapped around the plurality of discs and at least partially covering the base to enclose the plurality of discs securely to the base.
 2. The device of claim 1, further comprising a removable, substantially circular protective endplate having a central opening for engaging with the top portion of the spindle, the endplate being disposed atop the plurality of discs to protect and secure the plurality of discs to the spindle and base, and wherein the sheet material is wrapped around the plurality of discs and at least partially covering the base and the endplate to enclose the plurality of discs securely between the base and the endplate.
 3. The device of claim 1, further comprising attachment means for attaching and securing the spindle to the base.
 4. The device of claim 3, wherein the attachment means is selected from the group consisting of a twist lock connection, coupling grooves, a snap fit mechanism, a screw-on locking nut configured with a threaded spindle wherein the nut may be secured from the top side or bottom side of the base, and a detachable snap-on connection.
 5. The device of claim 3 wherein the base comprises a centrally located opening, and wherein the spindle comprises a flange at the bottom portion of the spindle, and wherein the flange is configured to engage the bottom side of the base to secure the spindle to the base.
 6. The device of claim 5 wherein the spindle further comprises a backing ring at the bottom portion of the spindle and above the flange, positioned so as to contact the upper side of the base and further secure the spindle to the base.
 7. The device of claim 1 wherein the base and spindle are formed of unitary construction.
 8. The device of claim 7 wherein the base and spindle are formed from extruded molding fabrication methods.
 9. The device of claim 1 wherein the base has an annular outer rib at an outer edge of the bottom side of the base, and a concentric inner rib on the bottom side of the base.
 10. The device of claim 1 wherein the base and spindle are made from a material selected from the group consisting of plastic, cardboard, metal, or a combination thereof.
 11. The device of claim 1 wherein the endplate is made of a material selected from the group consisting of plastic, paper, cardboard, metal, or a combination thereof.
 12. The device of claim 1 wherein the sheet material is shrink-wrap film or stretch wrap film.
 13. The device of claim 1 wherein the discs are optical data discs.
 14. The device of claim 1 wherein the device is configured to hold at least 25 discs.
 15. The device of claim 1 wherein the base and the endplate are of substantially the same diameter as the discs.
 16. The device of claim 12 wherein the sheet material wraps the device sufficiently to protect the device from the environment during shipping, handling and storage.
 17. The device of claim 12 wherein the sheet material wraps the device sufficiently to maintain a water resistant environment for the discs.
 18. A packaging device for securely holding and storing a plurality of discs, the device comprising: a) a base having a top side and a bottom side; b) an elongated spindle comprising a top portion and a bottom portion, the spindle being centrally located on the base and projecting from the base in a substantially perpendicular orientation to the base, wherein the spindle is configured to receive and secure a plurality of discs to the base; c) a removable, substantially circular protective endplate having a central opening for engaging with the top portion of the spindle, the endplate being disposed atop the plurality of discs to protect and secure the plurality of discs to the spindle and base; and d) attachment means for securing the endplate to the spindle.
 19. The device of claim 18 further comprising sheet material wrapped around the plurality of discs and at least partly around the base and the endplate to enclose the plurality of discs securely between the base and the endplate.
 20. The device of claim 19 wherein the sheet material wraps the device sufficiently to protect the device from the environment during shipping, handling and storage.
 21. The device of claim 18 wherein the attachment means is selected from the group consisting of a twist lock connection, a screw-on locking nut configured with a threaded spindle wherein the nut may be secured from the top side of the lid, and a detachable snap-on connection.
 22. A method for securely stacking, holding and storing a plurality of discs, the method comprising: a) providing a packaging device comprising: i) a base having a top side and a bottom side; ii) an elongated spindle comprising a top portion and a bottom portion, the spindle being centrally located on the base and projecting from the top side of the base in a substantially perpendicular orientation to the base, wherein the spindle is configured to receive and secure a plurality of discs to the base; and iii) a removable, substantially circular protective endplate having a central opening for engaging with the top portion of the spindle, the endplate being disposed atop the plurality of discs to protect and secure the plurality of discs to the spindle and base; b) stacking a plurality of discs onto the spindle; c) installing a endplate on the discs; and d) wrapping the plurality of discs and at least part of the base and of the endplate with sheet material to enclose the plurality of optical discs securely between the base and the endplate.
 23. The method of claim 22 wherein the packaging device further comprises attachment means for attaching and securing the spindle to the base, and wherein the method further comprises the step of attaching the spindle to the base.
 24. The method of claim 23 wherein the sheet material is shrink-wrap film and further comprising the step of heating the shrink-wrap film to shrink the film after the wrapping step.
 25. The method of claim 24 wherein the sheet material wraps the device sufficiently to protect the device from the environment during shipping, handling and storage. 